Melt Flow Index Research Articles

Mechanical recycling of polyamide 6 and polypropylene for automotive applications

AbstractThis study investigates the mechanical recycling of polyamide 6 (PA6) from discarded fishing nets and polypropylene (PP) from automotive battery scraps and household waste for automotive applications. The mechanical properties of both materials were evaluated through tensile, impact, and thermal testing, revealing that recycled PA6 (r‐PA6) and recycled PP (r‐PP) can achieve mechanical performance similar to virgin materials. Recycled PA6 was reinforced with 30% glass fiber (GF), significantly enhancing its tensile strength from 70 to 170 MPa, comparable with virgin PA6's (76 MPa). Furthermore, the tensile modulus of r‐PA6 increased from 7720 to 8500 MPa. Recycled PP was compounded with thermoplastic elastomers (TPE) and fillers, such as calcium carbonate (CaCO₃) and talc, improving its impact strength from 5 to 18 KJ/m2 and improving thermal stability, with a heat deflection temperature (HDT) reaching 95°C. The optimized formulations for r‐PP, particularly from automotive battery scrap, achieved a melt flow index (MFI) of 12–16 g/10 min, preventing molding defects. This study highlights the importance of controlled thermal treatments, appropriate additive use, and accurate processing conditions in producing high‐quality recycled polymer compounds.Highlights Recycled PA6 reinforced with 30% GF achieves a tensile strength of 170 MPa. Thermal treatment increases the tensile modulus of r‐PA6 to 8500 MPa, similar to virgin PA6. Incorporating TPE improves the impact strength of r‐PP to 18 KJ/m2. Calcium carbonate and talc enhance the thermal stability of r‐PP to 95°C. The melt flow index of r‐PP optimized to 12–16 g/10 min for better moldability.

Study of Mechanical and Thermal Properties of Environmentally Friendly Composites from Beer Bagasse.

The influence of bagasse fibres from beer manufacturing in mechanical, thermal, and rheological properties of three polymers (BioPE, PLA, and PP) has been studied in order to develop new environmentally friendly biocomposites for injection moulding applications. Totals of 10 wt%, 20 wt%, and 30 wt% of bagasse fibre (BSG) were added to the polymers by extrusion compounding, adding specific compatibilising additives, and injected samples were mechanically characterised by tensile, Charpy impact, and hardness tests. In addition, the fractures obtained after the impact test were observed using scanning electron microscopy (SEM) to assess the compatibility matrix filler. Characterisation of the thermal properties is also carried out by using differential scanning calorimetry (DSC) and thermogravimetry (TGA). Additionally, melt flow index of the biocomposites is also studied. An increase in the rigidity of the BioPE and PP composites was produced with the increase in BSG content, dealing with a decrease in maximum strain and impact resistance; whereas, in the filled BGS PLA biocomposites, Young's modulus was lower than that of the PLA material, improving the ductility of the PLA-BGS formulations. Compatibilisation effect was, therefore, different in the nine developed formulations, and the BGS content also influenced their thermal, mechanical, and rheological behaviours.

Dynamic behavior of melt electrospinning of blended polypropylene

Melt electrospinning is a promising process for fiber production without the need for solvents and with potential applications in various fields. In this study, we investigated the dynamic behavior of melt electrospinning under different blending ratios and process conditions. We used high melt flow index polypropylene and low molecular weight polypropylene, which were blended to lower the melt viscosity, and fibers were successfully manufactured through the melt electrospinning process. The effects of blending ratio and applied voltage on jet and drop formation, as well as fiber morphology, were examined. The results showed that blending low-molecular-weight polypropylene significantly influenced the jet and drop areas, leading to fluctuations in jet morphology. The size of the applied high voltage also had a high effect on the fiber diameter. Additionally, the viscosity reduction achieved through blending allowed for continuous jet formation and improved fiber production. These results provide valuable insights into controlling the process parameters and blending ratios in melt electrospinning, enabling the establishment of stable electrospinning conditions and precise control of fiber diameter.

Effect of toughening agent and flame‐retardant additives on the recycled polypropylene/oil palm empty fruit bunch laminated composites

AbstractThe increasing awareness of the environmental problems caused by the use of plastics has led to a demand for sustainable materials. The concept of turning waste into wealth has been considered in the study where the waste materials are value‐added into new composite materials that are recyclable, durable, and fire‐resistant. This effort aims to meet global environmental goals and the demand for high‐performance and sustainable building materials. The purpose of this current study is to develop laminated composites based on the combination of recycled plastic and oil palm empty fruit bunch (OPEFB). The addition of various loading of ammonium polyphosphate (APP) and 6 wt% of ethylene vinyl acetate (EVA) in the formulation was considered to enhance the performance of the composite laminates. The rPP and additives were compounded using a two‐roll mill. Then the rPP sheet and OPEFB were laminated using compression molding techniques. Results showed that rPP with addition of 30 wt% APP and 6 wt% EVA exhibited the highest thermal stability and the lowest melt flow index (MFI) value compared to other samples. Composites with 20 wt% APP and 6 wt% EVA showed 56% increase in flexural properties and 33% increase in impact strength compared to that of rPP/OPEFB composite sample without EVA. Addition of 30 wt% in recycled PP and OPEFB demonstrated self‐extinguished properties when exposed to fire compared to other samples. These findings indicated that rPP/OPEFB laminated composites with the addition of APP and EVA have a potential to be used in applications that require good strength and fire performance. The use of rPP/OPEFB composites with addition of APP and EVA has a potential to reduce virgin plastic consumption and agriculture material waste and establishing an environmentally friendly material for construction sector.Highlights Additives included in recycled PP enhance its thermal stability and reduce MFI. Recycled PP with OPEFB composite self‐extinguished at 30 wt% APP. The highest flexural strength is shown by composite laminates with 20 wt% APP and 6 wt% EVA. rPP/OPEFB laminates are ideal for building materials.

Impact of Runner Size, Gate Size, Polymer Viscosity, and Molding Process on Filling Imbalance in Geometrically Balanced Multi-Cavity Injection Molding.

The injection molding process is one of the most widely used methods for polymer processing in mass production. Three critical factors in this process include the type of polymer, injection molding machines, and processing molds. Polypropylene (PP) is a widely used semi-crystalline polymer due to its favorable flow characteristics, including a high melt flow index and the absence of a need for a mold temperature controller. Additionally, PP exhibits good elongation and toughness, making it suitable for applications such as box hinges. However, its tensile strength is a limitation; thus, glass fiber is added to enhance this property. It is important to note that the incorporation of glass fiber increases the viscosity of PP. Multi-cavity molds are commonly employed to achieve cost-effective and efficient mass production. The filling challenges associated with geometrically balanced layouts are well documented in the literature. These issues arise due to the varying shear rates of the melt in the runner. High shear rate melts lead to high melt temperatures, which decrease melt viscosity and facilitate easier flow. Consequently, this results in an imbalanced filling phenomenon. This study examines the impact of runner size, gate size, polymer viscosity, and molding process on the filling imbalanced problem in multi-cavity injection molds. Tensile bar injection molding was performed using conventional injection molding (CIM) and microcellular injection molding (MIM) techniques. The tensile properties of the imbalanced multi-cavity molds were analyzed. Flow length within the cavity served as an indicator of the filling imbalance. Additionally, computer simulations were conducted to assess the shear rate's effect on the runner's melt temperature. The results indicated that small runner and gate sizes exacerbate the filling imbalance. Conversely, glass fiber-filled polymer composites also contribute to increased filling imbalance. However, foamed polymers can mitigate the filling imbalance phenomenon.

Applied Investigation of Methyl, Ethyl, Propyl, and Butyl Mercaptan as Potential Poisons in the Gas Phase Polymerization Reaction of Propylene.

The polypropylene (PP) synthesis process is crucial in the plastics industry, requiring precise control as it directly impacts the catalytic activity and the final product's performance. This study investigates the effects of trace amounts of four different mercaptans on the polymerization of propylene using a fourth-generation Ziegler-Natta (ZN) catalyst. Various concentrations of these mercaptans were tested, and results showed that their presence significantly reduced the melt flow index (MFI) of the final PP. The most notable MFI decrease occurred at 37.17 ppm of propyl mercaptan and 52.60 ppm of butyl mercaptan. Methyl and ethyl mercaptan also reduced the MFI at lower concentrations, indicating that mercaptans act as inhibitors by slowing down the polymerization process and reducing the fluidity of molten PP. The highest MFI increase was observed at lower concentrations of each mercaptan, suggesting that smaller molecular inhibitors require less concentration. This trend was also seen in the catalyst's productivity, where lower concentrations of methyl mercaptan reduced PP production more effectively than higher concentrations of butyl mercaptan. Fourier transform infrared spectroscopy (FTIR) identified interactions between the mercaptans and the ZN catalyst. Computational analysis further supported these findings, providing insights into the molecular interactions and suggesting possible inhibition mechanisms that could impact the final properties of polypropylene.

DETERMINATION THERMAL AND MECHANICAL PROPERTIES OF NANO CARBON, GRAPHITE AND GRAPHENE REINFORCED RECYCLING POLYPROPYLENE COMPOSITE SAMPLES

Polymer-based plastic materials occupy a major place in daily life. However, due to the nature of polymer materials, low thermal resistance and mechanical properties of these products, the need for new and sustainable materials in the industry has increased. With the rapid technological developments in advanced manufacturing industries such as aviation, marine, motor sports and defence industry, lightweight and high-strength composite products have become even more important. In this context, in this study, 1% carbon, graphene and graphite particle reinforced Polypropylene (PP) composite material mixed in a twin-screw extruder and MA/G series injection moulding machine standard tensile test sample produced. Melt Flow Index (MFI), Heat Deformation Test (HDT), tensile test, Shore-D hardness measurement and density tests performed on these test samples. According to the results obtained from these tests, the mechanical and thermal properties of the test samples produced from different composite materials were determined. The best mechanical and thermal properties occurred in the graphene particle. It formed in graphite and carbon, respectively.

An Approach Toward Assessing Linear Low-Density Polyethylene/Alkali-Treated Peanut Shell Fiber Blends for Rotational Molding

In order to improve the mechanical properties of polymer composites, natural fibers are being employed more and more as reinforcements. However, incorporating natural fibers can be difficult in rotational molding, a process used to make hollow plastic objects like kayaks and fuel tanks. Bi-axial rotation is a procedure that can result in fiber aggregation and is challenging to regulate. The optimal combination of NaOH-treated peanut shell powder (TPSP) and linear low-density polyethylene (LLDPE) for rotational molding was examined in our research reported in the manuscript. Processability was assessed using a variety of testing techniques, such as Fourier transform infrared spectroscopy (FTIR), particle size distribution, bulk density, melt flow index (MFI), differential scanning calorimetry (DSC), and thermal gravimetric analysis (TGA). Significant peaks with TPSP concentrations in LLDPE ranging from 10 to 22% were shown by the FTIR. Blends of TPSP with LLDPE containing more than 18% TPSP were not acceptable for rotational molding due to poor flowability, as shown by particle size and bulk density investigations and supported by MFI data. According to our study, a 16% TPSP blend was the best formulation for rotational molding since it improved the thermal stability and increased the crystallinity by around 10%.

Comprehensive Investigation into the Impact of Degradation of Recycled Polyethylene and Recycled Polypropylene on the Thermo-Mechanical Characteristics and Thermal Stability of Blends.

The impact of degradation on plastics is a critical factor influencing their properties and behavior, particularly evident in polyethylene (PE) and polypropylene (PP) and their blends. However, the effect of photoaging and thermal degradation, specifically within recycled polyethylene (rPE) and recycled polypropylene (rPP), on the thermo-mechanical and thermostability aspects of these blends remains unexplored. To address this gap, a range of materials, including virgin polyethylene (vPE), recycled polyethylene (rPE), virgin polypropylene (vPP), recycled polypropylene (rPP), and their blends with different ratios, were comprehensively investigated. Through a systematic assessment encompassing variables such as melting flow index (MFI), functional groups, mechanical traits, crystallization behavior, microscopic morphology, and thermostability, it was found that thermo-oxidative degradation generated hydroxyl and carboxyl functional groups in rPE and rPP. Optimal mechanical properties were achieved with a 6:4 mass ratio of rPE to rPP, as validated by FTIR spectroscopy and microscopic morphology. By establishing the chemical model, the changes in the system with an rPE-rPP ratio of 6:4 and 8:2 were monitored by the molecular simulation method. When the rPE-rPP ratio was 6:4, the system's energy was lower, and the number of hydrogen bonds was higher, which also confirmed the above experimental results. Differential scanning calorimetry revealed an increased crystallization temperature in rPE, a reduced crystallization peak area in rPP, and a diminished crystallization capacity in rPE/rPP blends, with rPP exerting a pronounced influence. This study plays a pivotal role in enhancing recycling efficiency and reducing production costs for waste plastics, especially rPE and rPP-the primary components of plastic waste. By uncovering insights into the degradation effects and material behaviors, our research offers practical pathways for more sustainable waste management. This approach facilitates the optimal utilization of the respective performance characteristics of rPE and rPP, enabling the development of highly cost-effective rPE/rPP blend materials and promoting the efficient reuse of waste materials.

Synergistic Reinforcement with SEBS-g-MAH for Enhanced Thermal Stability and Processability in GO/rGO-Filled PC/ABS Composites.

The integration of compatibilisers with thermoplastics has revolutionised the field of polymer composites, enhancing their mechanical, thermal, and rheological properties. This study investigates the synergistic effects of incorporating SEBS-g-MAH on the mechanical, thermal, and rheological properties of polycarbonate/acrylonitrile-butadiene-styrene/graphene oxide (PC/ABS/GO) (PAGO) and the properties of polycarbonate/acrylonitrile-butadiene-styrene/graphene oxide (PC/ABS/rGO) (PArGO) composites through the melt blending method. The synergistic effects on thermal stability and processability were analysed by using thermogravimetry (TGA), melt flow index (MFI), and Fourier-transform infrared spectroscopy (FTIR). The addition of SEBS-g-MAH improved the elongation at break (EB) of PAGO and PArGO up to 33% and 73%, respectively, compared to the uncompatibilised composites. The impact strength of PAGO was synergistically enhanced by 75% with the incorporation of 5 phr SEBS-g-MAH. A thermal analysis revealed that SEBS-g-MAH improved the thermal stability of the composites, with an increase in the degradation temperature (T80%) of up to 17% for PAGO at 1 phr SEBS-g-MAH loading. The compatibilising effect of SEBS-g-MAH was confirmed by FTIR analysis, which indicated interactions between the maleic anhydride groups and the PC/ABS matrix and GO/rGO fillers. The rheological measurements showed that the incorporation of SEBS-g-MAH enhanced the melt flowability (MFI) of the composites, with a maximum increase of 38% observed for PC/ABS. These results demonstrate the potential of SEBS-g-MAH as a compatibiliser for improving the unnotched impact strength (mechanical), thermal, and rheological properties of PC/ABS/GO and PC/ABS/rGO composites, achieving a synergistic effect.

Evaluation of Mechanical Properties of Composite Material with a Thermoplastic Matrix Reinforced with Cellulose Acetate Microfibers.

Low-density polyethylene (LDPE) has been widely used in various applications due to its flexibility, lightness, and low production cost. However, its massive use in disposable products has raised environmental concerns, prompting the search for more sustainable alternatives. This study aims to investigate the mechanical properties achievable in a composite material utilizing low-density polyethylene (LDPE), potato starch (PS), and cellulose microfibrils (MFCA) at loadings of 0.05%, 0.15%, and 0.30%. Initially, the cellulose acetate microfibrils (MFCA) were produced via an electrospinning process. Subsequently, a dispersive mixture of the aforementioned materials was created through the extrusion and pelletizing process to form pellets. These pellets were then molded by injection molding to produce test specimens in accordance with ASTM D 638, the standard for tensile strength testing. The evaluation of the properties was conducted through mechanical tensile tests (ASTM D638), hardness tests (ASTM D 2240), melt flow index (ASTM D1238), and scanning electron microscopy (SEM). This study determined the influence of cellulose acetate microfibril loadings below 0.3% as reinforcement within a thermoplastic LDPE matrix. It was demonstrated that these microfibrils, due to their length-to-diameter ratio, contribute to an enhancement in the mechanical properties.

From Waste to Styrene-Butadiene (SBR) Reuse: Developing PP/SBR/SEP Mixtures with Carbon Nanotubes for Antistatic Application.

Styrene-butadiene rubber (SBR) waste from the shoe industry was repurposed to produce polypropylene (PP)-based compounds, with the aim of evaluating their antistatic potential. Styrene-ethylene-propylene (SEP) was added as a compatibilizing agent, while carbon nanotubes (MWCNT) were incorporated as a conductive nanofiller. The polymer compounds were processed in an internal mixer, and injection molded. The properties evaluated included torque rheometry, melt flow index (MFI), impact strength, tensile strength, Shore D hardness, electrical conductivity, heat deflection temperature (HDT), and differential scanning calorimetry (DSC), along with scanning electron microscopy (SEM) for morphology analysis. The production of the PP/SBR/SEP (60/30/10 wt%) compound resulted in a ductile material, enhancing impact strength and elongation at break to 161.2% and 165.2%, respectively, compared to pure PP. The addition of SEP improved the compatibility of the PP/SBR system, leading to an increase in the torque curve and a reduction in the MFI. Furthermore, the SBR/SEP combination in PP accelerated the crystallization process and increased the degree of crystallinity, suggesting a nucleating effect. Carbon nanotubes, in concentrations ranging from 0.5 to 2 phr (parts per hundred resin), were added to the PP/SBR/SEP system. Only the PP/SBR/SEP/MWCNT compound with 2 phr of MWCNT was suitable for antistatic applications, exhibiting an electrical conductivity of 4.52 × 10-07 S/cm. This was due to the greater distribution of MWCNT in the PP matrix, as demonstrated by SEM. In addition, remains tough at room temperature, with a 166% increase in impact strength compared to PP. However, there was a reduction in elastic modulus, tensile strength, Shore D hardness, and HDT due to increased flexibility. SBR waste can be reintegrated into the production chain to produce antistatic polymeric compounds, obtaining a tough material at room temperature.

A rigorous model for hydrogen response in industrial propylene polymerization loop reactors: From micro-mechanism to macro-behavior

In spite of playing a chain transfer agent role, the hydrogen activation effect in propylene polymerization with Ti-based Ziegler-Natta catalysts, so called “hydrogen response”, is usually explained by the dormant-site theory in polymer chemistry. However, how the micro-mechanism at the catalyst site scale affects the macro-behavior of industrial processes is unrevealed. This work aims at developing a rigorous model that can accurately describe hydrogen response and predict polymer chain microstructure for an industrial propylene polymerization process consisting of loop reactors in series. The model is comprised of a kinetic model, a thermodynamic model, and a macroscopic non-ideal loop reactor model. To describe hydrogen response, an elaborated kinetic model is established based on a consistent dormant site reactivation mechanism assuming a multi-site model. The model predictions are in good agreement with plant data, after taking the dormant sites reactivated by hydrogen into account. The proposed model is capable of fully assessing the effects of various process conditions, during steady-state and grade transition processes, on the macro-behavior (i.e., production, slurry density) as well as polymer properties (i.e., melt flow index, molecular weight distribution) in the industrial loop reactors. The underlying correlations are also discussed.

Poly(lactic acid)/poly(vinyl butyral) composites containing kaolin modified by acids and calcination

AbstractThe compatibility between two distinct polymers in the blend is important to maximize various properties of the blends. This study investigated the effects of kaolin modifications through acid and calcination treatments on the compatibility, molecular weight, its distribution, and various properties of poly(lactic acid) (PLA)/poly(vinyl butyral) (PVB) blends. In addition, the incorporation of the modified kaolin as a compatibilizer into the blends enhanced their mechanical and thermal properties, addressing the challenges of immiscibility between distinct polymers. The experimental approach included the utilization of scanning electron microscopy, gel permeation chromatography, differential scanning calorimetry, x‐ray diffraction, Fourier transform infrared spectroscopy, rheometer, and melt flow index to examine the structural, molecular, and thermal, mechanical and rheological behaviors of the composites. The changes in various molecular weights were correlated with other properties. The incorporation of surface‐treated kaolin into the blend improved the compatibility between PLA and PVB, exhibiting a singular melting temperature peak and a less distinct interface between two different polymers. This research contributed to the development of sustainable material solutions by demonstrating the potential of modified inorganic fillers in improving the performance of biodegradable polymer blends.

Ultrasound-Assisted Extrusion Compounding of Nano Clay/Polypropylene Nano Compounds.

The incorporation of nanoparticles can significantly enhance the properties of polymers. However, the industrial production of nanocomposites presents a technological challenge in achieving the proper dispersion of nanoparticles within the polymer matrix. In this work, a novel device is presented that can be seamlessly integrated with standard twin-screw extruders, enabling the application of ultrasonic vibration to molten polymeric material. The primary objective of this study is to experimentally validate the effectiveness of this technology in improving the dispersion of nanoparticles. To accomplish this, a comparative analysis was carried out between nanocomposites obtained through conventional compounding extrusion and those processed with the assistance of ultrasonic vibrations. The nanocomposites under investigation consist of a polypropylene (PP) matrix reinforced with nano clays (Cloisite 20A) at a target loading ratio of 5% by weight. To comprehensively evaluate the impact of the ultrasound-assisted compounding, various key properties were assessed, such as the melt flow index (MFI) to characterize the flow behavior, mechanical properties to evaluate the structural performance, oxygen barrier properties to assess potential gas permeability, and microstructure analysis using Scanning Electron Microscopy (SEM) for detailed morphology characterization. The results suggested an improvement in nanoparticle dispersion when using the ultrasound device, particularly when the intensity was adjusted to 60%.

Concept for recycling a small-scale plastic-based bioreactor in a close-loop – Technical approach

To accelerate biotherapeutic development whilst decreasing development time and project cost, small-scale multi-parallel bioreactors have been developed to maximize product yield and quality. These systems feature single-use plastic-based bioreactors for easy connection and fast turnaround. Despite well-known advantages, the perception of plastic and the lack of recycling options are raising concerns in the scientific laboratories’ community. One of the common objections to plastic circularity in life-science is the perceived “downcycling” effect of mechanical recycling. Therefore, the aim of this work was to establish the technical feasibility of a close-loop recycling concept for the main construction material of the small-scale bioreactor. Application tests (cell compatibility and cell culture) were performed and supported by quantitative physical and mechanical tests (tensile, melt flow index, light transmission). Results show that mechanically recycled polycarbonate could be re-used in the same application. A comparative life cycle assessment (LCA), based on a theoretical framework, showed with different scenarios that recycling would have a positive impact on Climate – Carbon – total within the boundaries. Even if the technical feasibility of such a concept is demonstrated through this study, several challenges remain for such a closed-loop recycling concept to be implemented at a commercial scale.

Toward the production of bioblends for the automotive sector: Reuse of recycled polyamide 6,6 to prepare super‐tough biopolyethylene

AbstractPlastics reuse is essential for promoting a sustainable future, especially by mitigating environmental impacts. Recycled polyamide 66 (PA66r) was reused for the produce biopolyethylene (BioPE)‐based blends, aiming to obtain a super‐tough material. Initially, a premix of PA66r with maleic anhydride‐grafted ethylene–propylene–diene (EPDM‐MA) was obtained in an internal mixer. Subsequently, the BioPE/PA66r and BioPE/(PA66r/EPDM‐MA) blends were processed in a twin‐screw extruder and injection molded. The rheological, mechanical, thermal, thermomechanical, structural, and morphological properties were investigated. Torque rheometry indicated an increase in the viscosity of the BioPE/(PA66r/EPDM‐MA) blends compared to BioPE/PA66r, which was confirmed by a reduction in the melt flow index (MFI). EPDM‐MA promoted greater stability in BioPE/(PA66r/EPDM‐MA) blends during processing, reducing the degradation rate and molecular weight loss. The BioPE/(PA66r/EPDM‐MA) blend with the 70/(15/15)% composition exhibited super‐tough behavior, with 822.4 J/m impact strength and 233% elongation at break. Scanning electron microscopy indicated a fracture with high plastic deformation, elongated fibrils, and refined particles (0.64 μm), confirming the high toughness. Apparently, a core‐shell morphology was formed, which favored maintaining tensile strength, Shore D hardness, and heat deflection temperature comparable to pure BioPE. The results indicate potential for application in the automotive industry, contributing to reintroducing recycled material into the production chain.

Injection molding of post-industrial recycled glass fiber reinforced polyphenylene sulfide (PPS GF40): industrial feasibility and material analysis

Polymer recycling has become increasingly important in recent decades due to economic and environmental benefits. Recycling provides a cost-saving material supply as well as avoids environmental spillage and enables resource conservation. Quantifying the changes in material properties due to recycling is a key aspect in establishing a circular economy, as it allows understanding the impact of using recycled materials on manufacturing and products. To date, research and industry have investigated the use of recycled materials for commodity and engineering polymers. For high performance plastics, this knowledge exists only at the laboratory scale. The present study comprehensively characterizes the properties of virgin and recycled glass fiber reinforced polyphenylene sulfide (PPS GF40) materials. The materials considered are commercially available to industry, and the recyclates have been reclaimed from post-industrial wastes by the material manufacturers. The results show that as the recycled content increases, the tensile strength of PPS GF40 revealed a similar value for a 50 % recyclate or decreases by 21 % for a regranulate due to both macromolecular shortening and fiber scission. In addition, the shrinkage of each material is quantified. Here, shrinkage increases with increasing result of recycled content. Increasing the amount of recycled material in the compound results in lower process forces in injection molding due to higher melt flow indices. With the help of these results, industrial products may be tailored to meet the properties of recyclate-based materials in order to conserve virgin material resources. In addition, material cost saving potentials are identified by economic calculations based on presently available industrial offers. In the light of the presented results, the introduction of recyclate-based PPS GF40 materials into industrial mass production can be assessed on the basis of mechanical and rheological properties as well as material costs. The overall objective of this study is to provide the aforementioned insights to exploit the economic and environmental benefits of polymer recycling on an industrial scale.

Parameter Optimization in FDM Filament Fabrication via Single Screw Extruder

The presence of polymer material filaments plays a crucial role in the realm of 3D printing. These filaments are utilized in 3D printing to create prototype products efficiently and cost-effectively. However, ensuring the production of high-quality prototype products necessitates the use of superior filaments characterized by consistent diameter and a round cross-section. Filaments are typically manufactured through an extrusion process using either a single screw extruder or a twin extruder. In this research, a DIY single-screw extruder was developed specifically for filament production. The main objective of this study is to generate quality filaments by optimizing the extruder parameters for various polymer materials. Three different polymers; Ethylene-vinyl Acetate (EVA), Polypropylene (PP), and Acrylonitrile Butadiene Styrene (ABS) were employed in this study. The research aimed to assess the melt flow index (MFI) to demonstrate viscous behavior and establish the ideal parameters for each material in the extrusion process. A total of 27 EVA material filament samples, 26 PP filament samples, and 26 ABS filament samples were successfully produced. Through analysis, optimal settings were identified for EVA, PP, and ABS filaments, resulting in high-quality production. The recommended parameters for producing quality EVA filaments included a temperature of 160°C, screw speed of 400 rpm, and take-up speed of 400 rpm. For PP filaments, the optimal settings comprised a temperature of 230°C, screw speed of 700 rpm, and take-up speed of 250 rpm. Lastly, ABS filament production was optimized with a temperature of 210°C, screw speed of 300 rpm, and take-up speed of 100 rpm. This project's outcomes are anticipated to have significant implications for future advancements in filament manufacturing processes.

Mono-axial stretching-induced growth of crystalline phase of melt-processed perfluoroalkoxy alkane (PFA) films for protecting inner layer of battery pouch films

Cast polypropylene (CPP) is employed as an inner layer of pouch films; however, CPP shows poor electrolyte, mechanical, and electrical stability, which can lead to instability during cell operation. In this study, we pioneered the use of perfluoroalkoxy alkanes (PFA) in the melt extrusion process to fabricate films based on their high melting flow index, establishing optimal conditions for producing uniform films. We further enhanced the functionality of these films by controlling the crystalline phase orientation through high-temperature uniaxial stretching, which is aimed at applications in battery pouch films. The stretched PFA films exhibited dramatically improved mechanical and insulation properties compared to traditional CPP films, 307.4% increase in tensile strength and 1,748.8% increase in breakdown strength, respectively. Based on these findings, we proposed that stretched PFA films, with their superior performance, are viable substitutes for CPP as the inner layer in battery pouch films. This research not only advances the material science of polymer films but also contributes to the development of safer and more efficient battery technologies.